The final charger assembly is started from the already mounted 3 assemblies for front panel, rear panel and main PCB. The Main circuit is connected to the front panel with the 4 battery wires (force and sense for battery positive and negative) of at least 2.5 sqmm or greater (preferred 4 sqmm), and with the flat cable for display, keys and serial communication routing. The rear panel has the power supply wiring of at least 2.5 sqmm or greater and the two wires for fan cooler supply. Keep at minimum all the wirings in order to maximize the charge and discharge capabilities.

Then the 3 assemblies are fitted in the plastic enclosure, the 1598ESGYPBK type from Hammond, without the aluminium front and rear panels. The front and rear FR4 panels are fitted using the small guides on the enclosure. The assembly is very easy and require only to flex the cables in order to fit all the assemblies inside the box.

Overall assembly view from the front panel.

Overall assembly view from the rear panel, power supply socket.

Overall assembly view from the rear panel, fan cooler air outlet.

Overall assembly view from the rear panel.

Overall assembly front view that shows the finished Universal Charger look and feel.

Overall assembly rear view that shows the finished Universal Charger look and feel.